Item selection and item loading error proofing apparatus

Abstract

Apparatus for error proofing in manufacturing and kitting operations and the like. A frame having two or four frame members utilizes light emitters and sensors on opposite sides to determine when the plane of the frame has been broken, and storage areas behind the frame have been accessed. This information is compared to programmed information to verify whether errors in accessing the storage area have occurred. The plane of the frame has a plurality of penetration zones distinguishable by their respective corresponding emitter and sensor pairs.

What is claimed is:  
     
       1. Apparatus for sensing completeness of a human operator's selection of components from sources of said components in a manufacturing, or assembly operation, comprising: 
       a frame;  
       a plurality of light sources supported by said frame for emitting beams of light defining a plane for placement between the operator and the sources of said components such that the operator must break said plane to access the sources of said components, at least one sensor associated with each light source and supported by said frame such that said sensor detects physical interruption of said light beam by the operator when the operator breaks said plane by accessing said source of components;  
       wherein each of said light sources and its associated at least one sensor is assigned to a specific penetration zone representing a segment of said plane such that the interruption of the light beam corresponding to each of said light sources and its associated at least one sensor occurs when the source behind said penetration zone is accessed by the operator;  
       wherein the size of each of said penetration zones is adjustable; and  
       a programmable logic controller (PLC) connected to each said sensor for receiving signals therefrom each time one of said light beams is interrupted by the operator's accessing one of said sources, said PLC further comparing said signals to information recorded in the PLC as to the correctness of accessing each source and signaling the operator when the operator has made an error in accessing a source.  
     
     
       2. The apparatus of claim  1  further comprising a plurality of indicator lights each of which is associated with one of said penetration zones. 
     
     
       3. The apparatus of claim  2  wherein said indicator lights are disposed on at least one indicator light bar above said penetration zones. 
     
     
       4. The apparatus of claim  1  wherein activation and deactivation of light beams from each light source is sequenced with respect to activation and deactivation of light beams from adjacent light sources, and wherein activation and deactivation of sensors corresponding to each light source is sequenced with respect to activation and deactivation of adjacent sensors. 
     
     
       5. The apparatus of claim  1  wherein the size of each of said penetration zones is adjustable by changing the number of light sources assigned to each such penetration zone. 
     
     
       6. The apparatus of claim  1  wherein the size of each of said penetration zones is adjustable by changing the number of sensors assigned to each such penetration zone. 
     
     
       7. The apparatus of claim  1  wherein the size of each of said penetration zones is adjustable by changing the number of light sources and sensors assigned to each such penetration zone. 
     
     
       8. Apparatus for sensing completeness of a human operator's selection of components from a source of said components or return of components to said source in a manufacturing, or assembly operation, comprising: 
       a doorway defining a plane for placement between the operator and the source of said components such that the operator must break said plane to access the source of said components, said doorway being a space between a first frame member and a second frame member spaced apart from and oppositely facing the first frame member;  
       a light source disposed on the first frame member for emitting a beam of light substantially parallel to the plane to be received by an opposing sensor disposed on the second frame member, such that said opposing sensor detects physical interruption of said light beam by the operator when the operator breaks said plane by accessing said source of components;  
       wherein light passing from said light source to its opposing sensor passes through a specific penetration zone representing a segment of said plane such that the interruption of the light beam corresponding to said light source and its opposing sensor occurs when the source behind said penetration zone is accessed by the operator; and  
       a programmable logic controller (PLC) connected to each said sensor for receiving signals therefrom each time said light beam is interrupted by the operator's accessing said source, said PLC further comparing said signal to information recorded in the PLC as to the correctness of accessing the source and signaling the operator when the operator has made an error in accessing the source.  
     
     
       9. The apparatus of claim  8  comprising a plurality of pairs of light sources and opposing sensors.